Patent Application
20220033175
The present disclosure generally relates to bulk bins and more particularly to a sleeve pack configured to be selectively erected as a bulk bin and selectively collapsed for storage when in disuse.
Bulk bins, which are sometimes referred to as bulk boxes, Gaylord bins, skid boxes, pallet boxes, octabins, etc., are commonly used for storing and shipping bulk quantities of goods. Typically, bulk bins are erected on pallets so that a forklift can move a bin while it is filled with goods. In an erected configuration, a bulk bin defines a large interior volume for receiving and containing goods in bulk. Some bulk bins are selectively collapsible for storing the bulk bin in a more space-efficient manner when it is not being used.
Certain bulk bins are formed from sleeve packs. Bulk bin sleeve packs typically include a base and two separate wall members that are arranged to form a perimeter wall of the bulk bin. The two wall members can be secured to one another to form the perimeter wall. The perimeter wall rests on the base with no attachment of the perimeter wall to the base.
In one aspect, a bulk bin sleeve pack for being repeatably erected to form a bulk bin having a bottom wall and a perimeter wall and collapsed when not in use comprises a base configured to form the bottom wall of the bulk bin. A first wall member is configured to form a portion of the perimeter wall of the bulk bin. The first wall member has a bottom edge margin, a top edge margin, and first and second side margins. The bottom edge margin is configured for attachment to the base so that the first wall member overlaps at least a portion of the base. A second wall member is configured to form another portion of the perimeter wall of the bulk bin. The second wall member has a bottom edge margin, a top edge margin, and first and second side margins. The bottom edge margin of the second wall member is configured for attachment to the base so that the first side margin of the first wall member overlaps the second side margin of the second wall member, the second side margin of the first wall member overlaps the first side margin of the second wall member, and the second wall member overlaps at least a portion of the base. Locking tabs are associated with at least one of the base and the first and second wall members. Locking openings are associated with at least one of the base and the first and second wall members. The locking openings oppose the locking tabs when the first and second wall members are attached to the base to form the perimeter wall of the bulk bin. The locking tabs are configured to be lockingly inserted into the locking openings to secure the first and second wall members to the base to form the bulk bin.
In another aspect, a bulk bin comprises a base having a perimeter. A perimeter wall extends circumferentially around a bulk bin interior and has a top edge margin and an opposite bottom edge margin arranged adjacent the perimeter of the base such that the base defines a bottom end of the bulk bin interior. An interlocking connection secures the base and the perimeter wall together. The interlocking connection includes at least one opening formed in either the base or the perimeter wall and at least one locking tab extending from the other of the base or the perimeter wall with the at least one locking tab extending through one of the at least one opening and locking the base and perimeter wall together.
In another aspect, a method of making a bulk bin sleeve pack comprises forming from a blank a perimeter wall member having an opening adjacent to a bottom edge margin of the perimeter wall member and forming from a blank a base having a perimeter. The base includes a locking tab and the perimeter wall member is sized and shaped for attachment to the base to form a perimeter wall on the base so that the opening of the perimeter wall member is aligned with the locking tab of the base.
Other objects and features will be in part apparent and in part pointed out hereinafter.
Corresponding reference characters indicate corresponding parts throughout the drawings.
Referring to
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As mentioned above, the bottom tray 112 is formed from a blank as shown in
Referring to
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The blank 120 includes a central panel 150 and first and second end panels 151, 152 are hingedly connected to the sides of the central panel. In one or more embodiments, living hinges are established along fold lines 154 formed in the blank 120 at the junctures between the central panel 150 and the first and second side panels 151, 152. The fold lines 154 can be formed in a suitable manner such as by heat scoring the fluted plastic material along the fold lines or by using a crease-forming machine, such as the Wegener Welding Crease-Folding Machine Model ESP 2000, available from Wegener Welding LLC in Burr Ridge, Ill. Suitably, the blank 120 is sufficiently flexible along the fold lines 154 to permit the left and right side wall members 120L, 120R to be folded in a substantially flat, three-layer configuration for storage. For example, in an exemplary collapsed configuration, the first side panel 151 is folded under the central panel 150 and the second side panel 152 is folded over the central panel so that the three panels are arranged adjacent one another and extend in substantially parallel planes. The first side panel 151 defines a first side margin of the blank 120 and the second side panel 152 defines a second side margin of the blank. As explained in further detail below, locking formations are formed in the first and second panels 151, 152 for forming interlocking connections 122 that, in the erected configuration, secure the first side margin of the left wall member 120L in overlapping engagement with the second side margin of the right wall member 120R and the second side margin of the left wall member in overlapping engagement with the first side margin of the right wall member.
The illustrated wall member blank 120 includes an upper locking tab 160, a lower locking tab 162 and an intermediate locking tab 162A that are formed in the first side panel 151 at spaced apart locations along the height of the first side margin of the blank. The second side panel 152 defines an upper opening 164, a lower opening 166 and an intermediate opening 166A at spaced apart locations along the height of the second side margin of the blank that are generally aligned with the upper locking tab 160, the lower locking tab 162 and the intermediate locking tab 162A along the height of the blank 120. The upper tab 160 and the upper opening 164 are each located adjacent the top edge margin of the blank and the lower locking tab 162 and the lower opening 166 are each located adjacent the bottom edge margin of the blank. Similarly, the intermediate tab 162A and intermediate opening 166A are located between the top and bottom edge margins, generally at about mid-height of the blank 120 in the illustrated embodiment. When the bulk bin 10 is erected as shown in
Although the illustrated wall blank 120 uses upper, lower and intermediate locking tabs 160, 162, 162A formed along the first side margin and upper, lower and intermediate openings 164, 166, 166A formed along the second side margin to form the first and second interlocking connections 122, it will be understood that other embodiments can use other arrangements of locking tabs and mating openings to form the connections. For example, other numbers of locking tabs and mating openings can be used to form each interlocking connection and/or the edge margins of the blank may be formed with different arrangements of tabs and openings without departing from the scope of the invention.
The tabs 160, 162, 162A are configured to be selectively and repeatably pushed into and removed from the openings 164, 166, 166A (e.g., at least about 25 times) without materially damaging the blanks 120 to an extent that they are no longer suitable for reuse. Each tab 160, 162, 162A is hingedly connected to the wall blank 120. Each tab 160, 162, 162A in the illustrated embodiment is formed by a generally three-sided cutout and is closely similar in construction and function to the tabs 161, 163 described in more detail below. In the illustrated embodiment, each tab 160, 162, 162A is formed as one piece of material with the wall blank 120.
The openings 164, 166, 166A in the illustrated embodiment are generally rectangular shape and have a height and a width. The width of the openings 164, 166, 166A are narrower than the portions of the tabs 160, 162, 162A received in the openings so that the interlocking portions push through the openings lockingly engage adjacent portions of the second side panel 52. The heights of the openings 164, 166, 166A are longer than the respective tabs 160, 162, 162A to provide space for grasping and manipulating the tabs when they are inserted through the openings.
Referring again to
The interlocking formations comprise at least one locking tab and at least one opening for a corresponding locking tab. Each locking tab extends through a corresponding opening to secure and lock the bottom tray 112 and the perimeter wall assembly 114 together. The locking tabs and openings can be a part of (e.g., formed in) either the bottom tray 112 or the perimeter wall assembly 114 (e.g., the left and right wall panels 120L, 120R). For example, in one embodiment the locking tabs extend from the bottom tray and the openings are formed in the perimeter wall assembly 114, in another embodiment the locking tabs extend from the perimeter wall assembly and the openings are formed in the bottom tray, and in still another embodiment the bottom tray and perimeter wall each include a mix of locking tabs and openings. In the illustrated embodiment, the locking tabs extend from the bottom tray 112 and the openings are formed in the perimeter wall assembly 114. The bottom tray 112 includes left and right locking tabs 161 and front and back locking tabs 163. The left and right locking tabs 161 are formed in the respective left and right rim panels 132L, 132R of the bottom tray 112 and the front and back locking tabs 163 are formed in the respective front and back rim panels 132F, 132B (see,
The openings 165, 167 are located adjacent to the bottom edge margin of the perimeter wall assembly 114. The locking tabs 161, 163 are located on the rim 132 of the bottom tray 112 and are each opposed by one (broadly, at least one) opening 165, 167 when the perimeter wall assembly 114 is attached to the bottom tray. When the bulk bin 110 is erected as shown in
The locking tabs 161, 163 are connected to the rim 132. Preferably, each side of the rim 132 (e.g., rim panels 132L, 132R, 132F, 132B) include at least one locking tab 161, 163 and each side of the perimeter wall assembly 114 includes at least one opening 165, 167 to secure each side of the perimeter wall assembly and each side of the bottom tray 112 together. In the illustrated embodiment, each side of the rim 132 includes two locking tabs 161, 163 and each side of the perimeter wall assembly 114 includes two openings 165, 167, although side with more or fewer openings/locking tabs are within the scope of the present disclosure.
Referring to
The openings 165, 167 in the illustrated embodiment are generally rectangular shape and have a height and a width. The width of the openings 165, 167 are narrower than the respective interlocking portions 189 of the tabs 161, 163 so that the interlocking portions push through the openings lockingly engage adjacent portions of the perimeter wall assembly 114. The heights of the openings 165, 167 are greater than the respective tabs 161, 163 to provide space for grasping and manipulating the tabs when they are inserted through the openings.
The interlocking portion 189 of each tab 161, 163 includes wing portions 191 that extend outward from a spine portion 192 generally aligned with the neck portion 187. The wing portions 191 define a width of the tab 161, 163 that is wider than the width of the corresponding opening 165, 167. Accordingly, the wing portions 191 must be deformed or bent to pass through the openings 165, 167. In one or more embodiments, as described in U.S. Pat. No. 9,290,290, which is hereby incorporated by reference in its entirety, the fluted plastic material of the blank 120 is oriented so that the flutes extend generally parallel to the spine portions 192 to define resilient living hinges along fold lines 193 between the spine portions and the wing portions 191. When the tabs 161, 163 are pushed through the openings 165, 167, an exterior surface of the perimeter wall assembly 114 engages the wings 191 and bends the wings along the fold lines 193 to fit the through the openings. After being inserted through the openings 165, 167, the tabs 161, 163 are configured to resiliently return toward their original configuration (e.g., by unbending along the fold lines 193 to a configuration in which the wing portions 191 are substantially planar with the neck portion 187) to lockingly engage an interior surface of the perimeter wall assembly 114 adjacent the openings. As may be seen in
The inner ends 191A of the wing portions 191 suitably define tapered inner corners (e.g., corners that are radiused, beveled, etc.) and outer ends 191B of the wing portions likewise may define tapered or chamfered outer corners. The tapered outer corners help facilitate inserting the tabs 161, 163 through the respective holes 165, 167 during deployment by gradually bending the wing portions 91 away from their planar orientation as the tabs pass through the holes to form the interlocking connections 123. Likewise, the tapered inner corners help facilitate removing the tabs by gradually bending the wing portions 191 away from their planar orientation as the tabs pass through the holes 165, 167 to disconnect or separate the interlocking connections 123 between bottom tray 112 and the perimeter wall assembly 114.
The sleeve pack 110 can be formed in a suitable manner, such as by stamping, cutting, deforming, punching, etc.
Having described the components of the bulk bin sleeve pack 110, deployment and storage of the bulk bin will now be described in greater detail. In general, it can be seen that the sleeve pack 110 comprises several separate components configured for selective deployment as a bulk bin. To erect the sleeve pack, the bottom tray 112 and the top tray 118 are assembled from the respective blanks. In addition, the left wall member 120L and the right wall member 120R are folded along the fold lines 154 to the U-shaped configurations shown in
To assemble the perimeter wall assembly 114, the left and right wall members 120L, 120R are positioned in heightwise alignment and so that the first side margin of the left wall member is arranged in overlapping engagement with the second side margin of the right wall member along the back side of the bulk bin and the second side margin of the left wall member is arranged in overlapping engagement with the first side margin of the right wall member along the front side of the bulk bin. In this position, the locking tabs 160, 162, 162A of left wall member 120L are generally aligned with the openings 164, 166, 166A of the right wall member 120R at the back side of the bulk bin 110 and the locking tabs of the right wall member are generally aligned with the openings of the left wall member at the front side of the bulk bin. To establish front and back interlocking connections 122, each pair of tabs 160, 162, 162A is pushed through the aligned openings 164, 166, 166A of the other panel 120L, 120R. As the tabs 160, 162, 162A are inserted, portions of the tabs resiliently bend away from their planar configurations to fit through the openings 164, 166, 166A. And when the tabs 160, 162, 162A are fully inserted, the bent portions resiliently return toward the planar configuration and lockingly engage portions of the respective second side panel 152 adjacent the mating opening 164, 166, 166A. At each interlocking connection, the tabs 160, 162, 162A are suitably bent along fold lines to be oriented substantially perpendicular to the overlapping side margins of the wall members 120A, 120R. The perpendicular tab orientation is thought to provide maximum resistance to inadvertent disengagement of the interlocking connections.
Before or after the perimeter wall assembly 14 is fully assembled, the left and right wall members 120L, 120R can be arranged so that the bottom edge margins thereof are nested with the rim 132 of the bottom tray 112. The openings 165 in the left and right bottom edge margins of the perimeter wall assembly 114 are generally aligned with the tabs 161, and the openings 167 in the front and back bottom edge margins are generally aligned with the tabs 161. The tabs 161, 163 can be folded into the perimeter wall assembly 114 so that the wings 191 are deformed to allow portions of the spines 192 and the wings to pass through the openings 165, 167. Once the wings 191 are fully on the interior of the perimeter wall assembly 114, they spring back toward their positions generally parallel with the spines 192. Thereafter, forces tending to separate the bottom tray 112 from the perimeter wall assembly 114 are resisted by engagement of the edges 191A with the interior surface of the perimeter wall assembly.
In use, the interior 116 of the bulk bin 110 is loaded with goods. Because the bulk bin 110 is made of fluted plastic boards that are formed to include fluid flow holes 133, 143, 149 the bulk bin is well-suited for receiving moist or damp goods such as produce. If desired, when the interior 116 of the bulk bin 110 is filled, the top tray 118 can be placed as a covering over the open top end of the bin. In this configuration, the top edge margin of the perimeter wall assembly 114 is nested in the rim 142 of the top tray. The tabs 161, 163 provide a good connection between the bottom tray 112 and the perimeter wall assembly 114 to resist separation in use. For example, if the bulk bin 110 loaded with produce is drenched with water and ice (as often occurs in use), the uplift caused by the water and ice on the perimeter wall assembly 114 is resisted by the tabs 161, 163 so that the perimeter wall assembly remains connected to the bottom tray 112. The bulk bin 110 is also constructed to be repeatedly assembled and disassembled for use and storage.
Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
As various changes could be made in the above products without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
